Structure based fluid distribution system

ABSTRACT

A climate controlled seat assembly includes a seat cushion that has an outer surface with a first side for supporting an occupant in a seated position and a second side, which generally faces in an opposite direction than the first side. An air passage extends from the first side to the second side of the seat cushion. A support member has a first side that is configured to provide support to the seat cushion and a second side. the first side and the second side of the support member generally face in opposite directions. A distribution passage is in communication with the air passage and is formed at least in part by a recess formed at least in part in one of the first side of the support member and the second side of the seat cushion.

PRIORITY INFORMATION

This application is a reissue of U.S. Pat. No. 8,539,624, which issuedSep. 24, 2013 from U.S. patent application Ser. No. 11/561,316, filedNov. 17, 2006, which claims priority to U.S. Provisional PatentApplication No. 60/809,459, filed May 31, 2006, the entirety entiretiesof both of which is are hereby incorporated by reference herein.

INCORPORATION BY REFERENCE

The entirety entireties of U.S. Pat. No. 8,539,624, filed as U.S. patentapplication Ser. No. 11/561,316 on Nov. 17, 2006 and issued on Sep. 24,2013, and U.S. Provisional Patent Application No. 60/809,459, filed May31, 2006, is are expressly incorporated by reference herein and made apart of the present specification.

BACKGROUND OF THE INVENTION

1. Field of the Invention

This invention relates to climate control. More specifically, thisinvention relates to climate control of a seat.

2. Description of the Related Art

Temperature modified air for environmental control of living or workingspace is typically provided to relatively extensive areas, such asentire buildings, selected offices, or suites of rooms within abuilding. In the case of vehicles, such as automobiles, the entirevehicle is typically cooled or heated as a unit. There are manysituations, however, in which more selective or restrictive airtemperature modification is desirable. For example, it is oftendesirable to provide an individualized climate control for an occupantseat so that substantially instantaneous heating or cooling can beachieved. For example, an automotive vehicle exposed to the summerweather, where the vehicle has been parked in an unshaded area for along period of time, can cause the vehicle seat to be very hot anduncomfortable for the occupant for some time after entering and usingthe vehicle, even with normal air conditioning. Furthermore, even withnormal air-conditioning, on a hot day, the seat occupant's back andother pressure points may remain sweaty while seated. In the wintertime, it is highly desirable to have the ability to quickly warm theseat of the occupant to facilitate the occupant's comfort, especiallywhere the normal vehicle heater is unlikely to warm the vehicle'sinterior as quickly.

For such reasons, there have long been various types of individualizedclimate control systems for vehicle seats. Such climate control systemstypically include a distribution system comprising a combination ofchannels and passages formed in the cushion of the seat. Climateconditioned air is supplied to these channels and passages by a climatecontrol device. The climate conditioned air flows through the channelsand passages to cool or heat the space adjacent the surface of thevehicle seat.

There are, however, problems that have been experienced with existingclimate control systems for seat assemblies. For example, thedistribution system is typically positioned along or near the topsurface of the cushion generally adjacent to the occupant. This cancompromise the comfort and/or the appearance of the seat. To solve thisproblem, additional components such as cover layers, additionalcushioning material etc. have been added to the seat.

SUMMARY OF THE INVENTION

Accordingly, one aspect of the present invention comprises a climatecontrolled assembly which includes a cushion and a support member. Thecushion has an outer surface comprising a first side for supporting anoccupant and a second side. The first side and the second side facegenerally in opposite directions. At least one air passage extends fromthe first side to the second side of the cushion. The support member hasa first side configured to provide support to the cushion and a secondside. The first side and the second side of the support member facegenerally in opposite directions. The support member comprising at leastone channel that is formed in the first side of the support member. Theat least one channel defines at least part of a distribution passagethat is in fluid communication with the at least one air passage.

Another aspect of the present invention comprises a method of assemblinga climate controlled assembly. In the method, a cushion is formed withpassages that extend from a first side of the cushion to a second sideof the cushion. A support member is formed with distribution channelsformed on a front face of the support member. The distribution channelsare aligned with the passages in the cushion. The second side of thecushion is coupled to the front face of the support member.

Another aspect of the present invention comprises a climate controlledassembly that has a cushion and a support member. The cushion has anouter surface comprising a first side for supporting an occupant and asecond side. The first side and the second side generally face inopposite directions. At least one air passage extends from the firstside to the second side of the cushion. A support member has a firstside configured to provide support to the cushion and a second side. Thefirst side and the second side of the support member generally face inopposite directions. A fluid transfer device is positioned between atleast a portion of the support member and at least a portion of thecushion. The assembly also includes means for distributing air from thefluid transfer device along at least a portion of the first side of thesupport member to the plurality of spaced apart air passages.

Another aspect of the present invention comprises a climate controlledassembly having a cushion and a support member. The cushion has an outersurface comprising a first side for supporting an occupant and a secondside. The first side and the second side generally face in oppositedirections. A support member has a first side configured to providesupport to the cushion and a second side. The first side and the secondside of the support member generally face in opposite directions. Afluid transfer device is configured to move fluid and is positioned atleast partially between at least a portion of the support member and atleast a portion of the cushion.

Another aspect of the present invention comprises a climate controlledassembly that includes a cushion that has an outer surface with a firstside for supporting an occupant and a second side, which generally facesin an opposite direction than the first side. An air passage extendsfrom the first side to the second side of the cushion. A support memberhas a first side that is configured to provide support to the cushionand a second side. The first side and the second side of the supportmember generally face in opposite directions. A distribution passage isin communication with the air passage and is formed at least in part bya recess formed at least in part in one of the first side of the supportmember and the second side of the cushion.

Another aspect of the present invention comprises a climate controlledassembly which includes a cushion that has an outer surface comprising afirst side for supporting an occupant and a second side. The first sideand the second side generally face in opposite directions. At least oneair passage extends from the first side to the second side of thecushion. The assembly further includes a support member having a firstside configured to provide support to the cushion and a second side. Thefirst side and the second side of the support member generally face inopposite directions. The support member further comprises at least oneopening that extends through the support member from the first side tothe second side. The assembly further includes an intermediate memberpositioned between the cushion and the support member. The intermediatemember comprises at least one open channel that is configured to placethe at least one opening in the support member in communication with theat least one air passage in the cushion.

Further features and advantages of the present invention will becomeapparent to those of ordinary skill in the art in view of the detaileddescription of preferred embodiments which follow, when consideredtogether with the attached drawings and claims.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a perspective view of a back portion of a seat assembly, whichincludes a climate control system that is configured in accordance witha preferred embodiment of the present invention;

FIG. 2 is a front view of the seat assembly of FIG. 1;

FIG. 3 is a front view of the seat assembly of FIG. 1 with a cushionremoved;

FIG. 4 is a cross-sectional view of the seat assembly of FIG. 1 takenalong line 4-4 of FIG. 2;

FIG. 5 is a cross-sectional view of the seat assembly of FIG. 1 takenalong line 5-5 of FIG. 2; and

FIG. 6 is a schematic illustration of the seat assembly and climatecontrol system of FIG. 1.

FIG. 7 is a perspective view of an assembly of a climate controlled seatsystem.

FIG. 8 is a front view of an intermediate layer of the climatecontrolled seat system of FIG. 7.

FIG. 9 is a front view of a cushion layer of the climate controlled seatsystem of FIG. 7.

FIG. 10 is a perspective view of an assembly of a climate controlledseat system.

FIG. 11 is a perspective view of the cushion layer of the climatecontrolled seat assembly of FIG. 10.

FIG. 12 is a front view of the cushion layer of the climate controlledseat system of FIG. 10.

FIG. 13 is a perspective view of an assembly of a climate controlledseat system.

FIG. 14 is a perspective view of the cushion layer of the climatecontrolled seat assembly of FIG. 13.

FIG. 15 is a front view of the cushion layer of the climate controlledseat assembly of FIG. 13.

FIG. 16 is an embodiment of a frame of the climate controlled seatsystem of FIG. 7.

FIG. 17 is an embodiment of an intermediate layer of the climatecontrolled seat system of FIG. 7.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

FIGS. 1 and 2 are front perspective and front views of an embodiment ofa climate controlled seat assembly 30. As shown, the seat assembly 30comprises a backrest 34, which can be coupled and/or used in combinationwith a seat portion (not shown) to form a seat. The seat assembly 30also includes a climate control system 36, which will be described inmore detail below with reference to FIGS. 3-6.

When an occupant sits in the seat assembly 30, the occupant's seat islocated on the seat portion and the occupant's back contacts a frontsurface 48 of the backrest portion 34. The backrest 34 and the seatportion cooperate to support the occupant in a sitting position. Theseat assembly 30 can be configured and sized to accommodate occupants ofvarious size and weight.

In the illustrated embodiment, the seat assembly 30 is similar to astandard automotive seat. However, it should be appreciated that certainfeatures and aspects of the seat assembly 30 described herein may alsobe used in a variety of other applications and environments. Forexample, certain features and aspects of the seat assembly 30 may beadapted for use in other vehicles, such as, for example, an airplane, aboat, wheelchairs, or the like. Further, certain features and aspects ofthe seat assembly 30 may also be adapted for use in stationaryenvironments, such as, for example, a chair, a sofa, a theater seat, andan office seat that is used in a place of business and/or residence. Inaddition, certain features and aspects of the seat assembly 30 can beadapted for use in devices that do not support a person in a seatedposition, such as, for example, beds.

With continued reference to FIGS. 1 and 2, the backrest 34 has a frontside 54, a rear side 56, a top side 58 and a bottom side 60. Althoughnot illustrated, the backrest 34 can include a pair of sides that extendbetween the top side 58 and bottom side 60 for providing lateral supportto the occupant of the seat assembly 30.

As shown, the backrest 34 is generally formed by a cushion 72, which iscovered with an appropriate covering material (not shown), such as, forexample, upholstery, vinyl or leather. The cushion 72 is typicallysupported on a frame or support member 74. In some embodiments, springsmay be positioned between the frame 74 and the cushion 72. The frame 74provides the seat assembly 30 with structural support while the cushion72 provides a soft seating surface. The covering material, in turn,provides an aesthetic appearance and soft feel to the surface of theseat assembly 30. The cushion 72 also has a rear side 73, which isgenerally opposite the front side 48 54 of the cushion 72 and adjacentto the frame 74.

The cushion 72 can be a typical automotive seat cushion foam or othertypes of materials with suitable characteristics for providing supportto an occupant. Such materials include, but are not limited to, closedor open-celled foam.

FIG. 3 is a front view of the seat assembly 30 of FIGS. 1 and 2 with thecushion 72 removed to illustrate the exposed front face 75 of the frame74. As shown, the frame 74 of the backrest 34 of the seat assembly 30forms, at least in part, a portion a backrest fluid distribution system76. The distribution system 76 comprises an inlet channel or recess 78,which can be formed in the front face 75 of the frame 74. In theillustrated embodiment, the inlet channel 78 comprises a generallyu-shaped channel or recess. In modified embodiments, the inlet channel78 can have a different shape (e.g., v-shaped, or semi-circular).

With continued reference to FIG. 3, the distribution system 76 alsoincludes at least one, and often, a plurality of distribution channelsor recesses 80, which extend from the inlet channel 78. In theillustrated embodiment, the inlet channel 78 extends in a generallyvertical direction along the front face 75 of the frame 74. Thedistribution system 76 includes a pair of distribution channels 80,which extend horizontally in opposite directions from the inlet channel78. The distribution channels 80 then turn approximately 90 degrees andextend in a generally downwardly direction generally parallel to theinlet channel 78. However, it should be appreciated that the illustratedshape, orientation and number of inlet and distribution channels 78, 80is one example that can be used to distribute a fluid along the frame74. Modified embodiments of the present invention can utilize differentnumbers, shapes, and orientations of the inlet and distribution channels78, 80. In addition, the inlet and distribution channels 78, 80 can becombined or subdivided.

As shown in FIG. 3, the inlet channel 78 can be in communication with arecess 82 for a fluid module 92 (not shown in FIG. 3). The recess 82 canbe configured such that when the fluid module 92 is positioned withinthe recess 82 an outlet of the fluid module is in communication with theinlet passage 78. The fluid module also includes an inlet, which is incommunication with a fluid module inlet channel 98, which extends fromthe recess 82. The recess 82 can include recessed flanged portions 101which are configured to receive mounting flanges coupled to the fluidmodule 92. In this manner, the fluid module 92 can be positioned withinthe recess 82 such that its outlet is in fluid communication with theinlet channel 78 and its inlet is in fluid communication with the fluidmodule inlet channel 98.

As will be explained below, the fluid module 92 can be configured toprovide conditioned air (and/or to remove air in some embodiments) tothe distribution systems 76. In this manner, the fluid module 92provides a fluid flow to either warm or cool the front surface 48 of thebackrest 34 as will be explained below. In such embodiments, the fluidmodule 92 can include heating and/or cooling elements. In modifiedembodiments, the fluid module 92 can be configured to provideunconditioned (e.g., ambient) air to the front surface of the backrest34. In such an embodiment, the fluid module can include a pumpingelement (e.g., an axial or radial fan).

With reference to FIGS. 4-5, the front surface 75 of the frame 74 can becovered by the cushion 72 to define distribution passages 83 fortransporting air from the fluid module 92 along the front surface 75 ofthe frame 74. The cushion 72 and the fluid module inlet channel 98define, in turn, a fluid module inlet passage 99 (see FIG. 5) fortransporting air from outside the seat assembly 30 to the fluid module92.

As shown in FIG. 4, a plurality of orifices 100 can extend through thecushion. 72 for delivering air to and/or from the distribution passages83. Each orifice 100 includes an opening 102 on the front surface 48 ofthe cushion 72 (see also, FIGS. 1 and 2) and communications with adistribution passage. In this manner, air can be either delivered fromthe distribution passages 83 to the front surface 48 of the cushion 72and/or air can be removed from the front surface 48 of the cushion 72and be withdrawn into the distribution passages 83. In the illustratedembodiment, the orifices 100 communicate with the distribution channels80 but in modified embodiments the orifices 100 can communicate, inaddition to or alternatively, with the inlet channel 78.

As mentioned above, the cushion 72 may be formed from a typical cushionmaterial, such as, for example, an open or closed cell foam orcombination thereof. In one embodiment, the cushion 72 is made of foamthat is pre-molded to form the orifices and/or the channels 80. Inanother embodiment, the orifices 80 100 may be formed by removing (e.g.,cutting or boring) foam out of the seat cushion 72. The cushion 72 canbe coupled to the frame 74 in a variety of manners, such as, forexample, through adhesives, tie-downs, etc. Preferably, the cushion 72is coupled to the frame in a manner such that the distribution passagesare substantially sealed with respect to air flow. In modifiedembodiments, an intermediate member (e.g., a sealing pad, sealant and/orcoating) can be placed between the cushion 72 and the frame 74 to form apart of the distribution passages 83. In addition to or in thealternative, an intermediate member can be placed within and/or alongthe channels 78, 80 in the frame 74. Such an intermediate member can beadvantageous if the frame 74 is made of an air permeable material.

In certain embodiments, a distribution layer (not shown) can be disposedbetween the cushion 72 and the seat covering. The distribution layer canbe configured to spread the air flowing through the openings 102 alongbottom surface of the covering. To permit airflow between thedistribution layer and the spaces proximal to the front surface 48 ofthe backrest 34, the covering may be formed from an air-permeablematerial. For example, in one embodiment, the covering comprises anair-permeable fabric made of natural and/or synthetic fibers. In anotherembodiment, the covering is formed from a leather, or leather-likematerial that is provided with small openings or apertures. In certainembodiments, the distribution layer can comprise a fibrous or honeycombmaterial.

The climate control seat assembly 30 and distribution system 76 has beendescribed with reference to a backrest 30. However, as mentioned above,it is anticipated that the certain features of the climate controlassembly 30 and distribution system 76 can be applied to a seat portionof a seat assembly 30. In addition, it is anticipated that certainfeatures and features of the distribution system 76 can be applied toside panels of a seat assembly 30. Thus, for example, with respect to anembodiment for a seat portion, the exposed front face 75 of the frame 74can correspond to a top face of a frame for the seat portion. In asimilar manner, the rear side 73 of the seat cushion can correspond to abottom side of a cushion for the seat portion.

As mentioned above, the frame 74 provides support for the cushion 72. Inaddition, in the illustrated embodiment, the frame 74 advantageouslyforms and/or provides space for at least part of the distribution system76. This arrangement is advantageous because it positions thedistribution system 76 further from the front surface 48 of the backrest34. This improves the overall seat appearance and comfort. In addition,in the prior art, when the distribution system is positioned near on thefront surface of the seat, additional components (e.g., inserts, pads,distribution layers, etc.), are often used in order to improve thecomfort and/or appearance of the seat. Such components are not requiredwith the seat assembly described above. In addition, the frame 74 in theillustrated embodiment can be used to mount and/or support the fluidmodule 92 and/or other components of the fluid distribution system 76.For example, in the illustrate embodiment, recessed flanged portions 101can be provided in the frame 74 for supporting corresponding flangedportions on the fluid module 92. This arrangement of positioning thefluid module 92 between at least a portion of the cushion 72 and atleast a portion of the frame 74 also conserves space and improves theappearance of the seat assembly 30.

The frame 74 can be formed from a variety of materials given the goal ofproviding a distribution system 76 as described above. For example, inone embodiment, the frame 74 can be formed from foam or plastic (or acombination thereof) that is molded or otherwise shaped to form thedistribution system 76 described above. In a modified embodiment, theframe can comprise a metallic material (e.g., steel) which has beenstamped or otherwise formed the channels and recesses described above.In another embodiment, a combination of materials (e.g., metallic, foam,and/or plastic) is used to form the frame 74. In general, a foam orplastic frame 74 is preferred because it provides a lower thermal massas compared to a metallic frame.

Given the goal of distributing air through the cushion 72 and to thefront surface 48 of the seat assembly 30, those of skill in the art willrecognize that the distribution system 76 can be modified in severaldifferent manners. For example, as mentioned above, the shape and/ornumber of channels 78, 80, 98 can be modified. In other embodiments, theorifices 100 can be replaced with porous and/or air permeable portionsof the cushion 76 72 which are in communication with the distributionsystem 76.

In yet another embodiment, the channels and/or recesses can also or inthe alternative be formed in the rear surface 73 of the cushion 72. Insuch an embodiment, the fluid module 92 can be positioned within arecess formed in the rear surface 73 of the cushion 72. The channelsand/or recesses described above can also be formed in the rear surface73 of the cushion 72. Such channels and/or recesses can replace and/orbe used in combination with the channels 78, 80, 98 described above.Thus, in such embodiments, the fluid module 92 and/or the channels andrecesses can also be positioned between at least a portion of thecushion 72 and at least a portion of the frame 74.

In another embodiment, the fluid module 92 can be positioned within arecess or channel in the rear surface 73 of the cushion 72 and/or thefront surface 75 of the frame while one or more distribution passagesextend along the front surface 48 of the cushion. In such anembodiments, the distribution passages can be arranged as described inU.S. Patent Publication 2005-0264086, published Dec. 12, 2005, theentirety of which is hereby incorporated by reference herein. In such anembodiment, the system can be used without or without the insertsdescribed in U.S. Patent Publication 2005-0264086. In certainembodiments, the thermal module inlet passage 99 can extend between thecushion 72 and frame 74 as described above and/or an inlet passage canextend through a portion of the frame 74.

In other embodiments, the distribution passages 93 can be positionedbetween the cushion 72 and the frame 74 while the fluid module 92 is notpositioned between the frame 74 and the cushion 72. For example, thefluid module 92 can be positioned on a rear side of the frame 74 andconnected to the distribution passages 83 through a passage formed inthe frame 74. In a modified embodiment, the fluid module 92 can be incommunication with the thermal module inlet passage 99 and positionedbelow the backrest 34.

FIG. 6 is a schematic illustration of the climate control system 36described above. Specifically, this Figure schematically illustrates thefluid module 92 and the distribution system 76 in the backrest 34. Asmentioned above, the fluid module 92 can provide fluid flow to eitherwarm or cool the front surface 48 of the backrest 34. Specifically, theclimate control apparatus 36 preferably provides conditioned air that iseither heated or cooled relative to the temperature of the front surface48 of the backrest 32 34. In this illustrate, the fluid module 92 shownpositioned outside of the frame 74 and cushion 72 according to theembodiment described in the previous paragraph.

In the illustrated embodiment, the fluid module 92 preferably includes athermoelectric device 110 for temperature conditioning (i.e. selectivelyhealing or cooling) the fluid flowing through the device 110. Apreferred thermoelectric device 110 is a Peltier thermoelectric module,which is well known in the art. The illustrated fluid module 92preferably also includes a main heat exchanger 112 for transferring orremoving thermal energy from the fluid flowing through the module 92 andto the distribution systems 76. The module 92 also preferably includes asecondary heat exchanger 113 that extends from the thermoelectric device110 generally opposite the main heat exchanger 112. A pumping device 114is preferably associated with each fluid module 92 for directing fluidover the main and/or waste heat exchangers 112, 113. The pumping device114 can comprise an electrical fan or blower, such as, for example, anaxial blower and/or radial fan. In the illustrated embodiment, a singlepumping device 114 can be used for both the main and waste heatexchanges 112, 113. However, it is anticipated that separate pumpingdevices may be associated with the secondary and heat exchangers 112,113.

It should be appreciated that the fluid module 92 described aboverepresents only one exemplary embodiment of a device that may be used tocondition the air supplied to the distribution system 76. Any of avariety of differently configured fluid modules may be used to provideconditioned air. Other examples of fluid modules that may be used aredescribed in U.S. Pat. Nos. 6,223,539, 6,119,463, 5,524,439 or5,626,021, which are hereby incorporated by reference in their entirety.Another example of such a fluid module is currently sold under thetrademark Micro-Thermal Module™ by Amerigon, Inc. In another example,the fluid module may comprise a pump device without a thermoelectricdevice for thermally conditioning the air. In such an embodiment, thepumping device may be used to remove or supply air to the distributionsystem 76. In yet another embodiment, the fluid module 92 can share oneor more components (e.g., pumping devices, thermoelectric devices, etc.)with the vehicles general climate control system.

In operation, fluid in the form of air can be delivered from the fluidmodule 92, to the distribution system 76. As described above, the airflows through the passages 83, into the orifices 100 and through thecovering. In this manner, conditioned air can be provided to the frontsurface 48 of the backrest 34.

In a modified embodiment, air from the front surface 48 can be drawnthrough the covering into the orifices 100. The air then can flowthrough the distribution passages 83. In this manner, the climatecontrol system 36 can provide suction so that air near the surface ofthe seat assembly 30 is removed.

FIG. 7 illustrates a perspective view of an assembly of a climatecontrolled seat assembly 150. The climate controlled seat assembly 150comprises a back rest which can be coupled and/or used in combinationwith a seat portion (not shown) to form a seat which can be similar toprevious embodiments as described in FIGS. 1-6.

In the illustrated embodiment, the seat assembly 150 generally includesa climate controlled system 152 which can be substantially similar tothe climate control system 36 of FIG. 6, a frame 154, and a cushion 156.The seat assembly 150 further includes a seat cover 158. The frame 154provides the seat assembly 150 with structural support while the cushion156 provides a soft surface for an occupant. The cover 158, in turn,provides an aesthetic appearance and soft feel to the surface of theseat assembly 150. The seat cushion 156 further includes an intermediatelayer 160 and a cushion layer 162 which will be discussed in greaterdetail below.

With continued reference to FIG. 7, the frame 154 is preferably a rigidand substantially planar structure with a centrally located passageway155 which is configured to maintain communication between the climatecontrol system 152 and the cushion 156. The frame 154 is preferablysufficiently rigid or semi rigid so as to structurally support the seatassembly 150.

The intermediate layer 160 of the cushion 156 is configured todistribute air from the climate controlled system 152 evenly throughoutthe cushion layer 162. The cushion layer 162 inturn, is configured todistribute the air to a front surface 164 of the seat assembly 150. Fromthe cushion layer 162, the air preferably passes through the seat cover158 to the front surface 164. While the air is being distributedthroughout the front surface 164, an occupant is preferably in contactwith the seat assembly 150 at the front surface 164 of the seat cover158.

With reference to FIG. 8, the intermediate layer 160 of the cushion 156preferably comprises a channel system 166. The channel system 166preferably passes through a thickness of the intermediate layer 160. Inone embodiment, the intermediate layer 160 is made of material that ispre-molded to form a channel system 166. In another embodiment, thechannel system 166 may be formed by removing (e.g., cutting or boring)foam out of the intermediate layer 160. The channel system 166 includesa central entrance portion 170 and four distribution channels 172. Thedistribution channels 172 preferably extend from the central portion 170and extend outwards towards distal ends of the intermediate layer 160.The channel system 166 loosely resembles an X-shape that extends fromthe corners of the intermediate layer 160 and crosses at the centralportion 170. The channel preferably passes through the layer 160completely forming open channels that allow air from the climatecontrolled system 152 to flow evenly throughout the distributionchannels 172. As will be appreciated by one skilled in the art, anysuitable shape of the channel system 166 can be utilized in theintermediate layer 160. Such alternative shapes may include an H-shape,a Y-shape, or simply a large rectangle that occupies a majority of theintermediate layer 160.

Preferably, a cross-sectional shape of the distribution channels 172 isgenerally rectangular. However, the cross-section of the channels 172can be modified to accommodate any desired flow characteristics oroptimal hydraulic shapes such as a V-shape or inverted V-shape. Theintermediate layer 160 is preferably formed from typical automotive seatcushion foam. However, the intermediate layer 160 can also beconstructed from other types of materials with suitable characteristicsfor providing support to an occupant and for holding the shape of thechannel system 166. For example, certain preferred materials may includebut are not limited to closed or open celled foam. In the embodimentshown in FIG. 7-9 it may be also suitable to make the intermediate layer160 out of a rigid material such as injection molded plastic or plywood.

FIG. 9 illustrates a top view of the cushion layer 162. The cushionlayer 162 preferably has a plurality of apertures 173 which pass througha thickness of the cushion layer 162. In the illustrated embodiment, thecushion layer 162 includes 14 apertures which closely follow the path ofthe channel system 166 of the intermediate layer 160. This patternallows air flowing through the distribution channels 172 to be evenlydistributed to the apertures 173. The air can then pass from thedistribution channels 172 through the apertures 173 and proceed towardthe front surface 164.

In one embodiment, layer 162 is made of material that is pre-molded toform the apertures 173. In another embodiment, the apertures 173 may beformed by removing (e.g., cutting or boring) foam out of the cushionlayer 162. It will also be appreciated by one skilled in the art thatthe apertures 173 may comprise any number of apertures in anyconfiguration to optimize hydraulic characteristics of air transfer. Forexample, there may be a greater or lesser number of apertures of varyingsize and shape in the cushion layer 162.

Similar to the intermediate layer 160 of FIG. 8, the cushion layer 162of FIG. 9 is preferably constructed from typical automotive seat cushionfoam. However, once again, other types of materials with suitablecharacteristics may be used. For example, certain preferred materialsmay include but are not limited to close or open cell foam. It can alsobe appreciated by one skilled in the art that the intermediate layer 160of FIG. 8 and the cushion layer 162 of FIG. 9 may be made of asemi-rigid or rigid material. Such a configuration may preferably beused alternatingly with having one of the layers 160 or 162 rigid withthe other layer a soft cushion.

With returning reference to FIG. 7, the climate controlled seat assembly150 includes a seat cover 158 which preferably covers at least a portionof the layers 162 and 160. The material is preferably an air permeablefabric permitting air flow from the cushion layer 162 to front surface164. For example, in one embodiment, the seat cover 158 comprises anair-permeable fabric made of natural and/or synthetic fibers. In anotherembodiment, the covering is formed from a leather, or leather-likematerial that is provided with small openings or apertures.

FIG. 10 illustrates another embodiment of a climate controlled seatassembly 150 150a. Similar to the embodiment illustrated in FIG. 7, theembodiment illustrated in FIG. 10 includes a climate controlled system152, a frame 154, layers 160 and 162 and a seat cover 158. The frame154, the intermediate layer 160, the cover 158, and the climatecontrolled system 152 are substantially similar to the climatecontrolled seat assembly embodiment of FIG. 7. The cushion layer 162162a of FIG. 10 does present some differences from the cushion layer 162shown in FIGS. 7-9 as will be described below.

The cushion layer 162 162a shown in FIGS. 11 and 12 is preferably agel-filled layer. Although it is preferable that the layer begel-filled, it may be filled with any suitable fluid or particulate thatmay produce a comfortable feel to an occupant. The cushion layer 162162a preferably comprises a lower layer 174 and an upper layer 176. Thelower layer 174 and the upper layer 176 are preferably fused togetheralong outer edges to form gel pockets 184 in between the two layers 174and 176. The upper layer 176 and the lower layer 174 are further fusedtogether along a channel system 178.

The channel system 178 preferably includes an upper channel 180 and alower channel (not shown). The upper channel 180 is preferably formed inthe upper layer 176 and the lower channel (not shown) is preferablyformed in the lower layer. The upper channel 180 and the lower channel(not shown) are formed by the fusing of the layers 174 and 176 about anapproximate planar centerline of the cushion layer 162 162a. The fusedportion draws the layers 174 and 176 towards the centerline of thecushion layer 162 162a and the fluid in between the layers 174 and 176maintains a thickness around the sides of the fused upper channel 180and lower channel (not shown). Thus the raised thickness provided by thefluid produces the sides of the upper channel 180 and the lower channel(not shown). At the base of the upper channel 180 and the lower channel(not shown) are apertures 182 which pass through the cushion layer 162.Similar to the cushion layer 162 of FIG. 7, the apertures 182 of thecushion layer 162 162a of FIG. 11 closely follow the channel system 166of the intermediate layer 160. This allows the air from the channelsystem 166 178 to pass through the apertures 182 and to the occupantsitting on the climate controlled seat assembly 150 150a.

The channel system 178 of the cushion layer 162 162a preferablycomprises the same general X-shape of the channel system 166 of theintermediate layer 160. As discussed above with reference to the layers160 and 162 162a of FIGS. 7-9, the channel system 178 can be made in anypreferable shape. Furthermore, the channel system 178 may not be used atall and the apertures 182 may be formed individually with small areas offused layers 174 and 176 adjacent to the apertures 182. Such aconfiguration may allow for more fluid or particulate to be used in thecushion layer 162 162a.

Another possible configuration of the cushion layer 162 162a may utilizepre-formed apertures 182 in the cushion layer 162 162a. Such aconfiguration may comprise the layers 174 and 176 to be formed from asingle piece of plastic, or other suitable material, that may notrequire fusing of two separate layers. Such a configuration may includethe apertures 182 to be pre-formed through the layer 162 162a so as tocrate a seamless pouch to contain a fluid or particulate. Furthermore,such a seamless pouch may comprise channels or apertures to be formed inthe cushion layer 162 162a.

The channel system 178 of the cushion layer 162 162a further definesfour gel pouches 184. The gel pouches 184 are preferably configured toinclude a fluid or particulate within the pouch that is movable withinthe pouch. This movability of the fluid within the pouch 184 allows forthe cushion layer 162 162a to add comfort to the occupant by displacingfluid away from pressure points between an occupant and the seatassembly 150 150a.

The cushion layer 162 162a is preferably made of a plastic material butcan be easily formed of any other suitable material that may contain afluid or particulate. The plastic material may offer certain benefitswhen sealing the upper layer 176 and the lower layer 174 in that it caneasily be sealed by heat. It may be also appreciated by one in the artthat the apertures 182 preferably pass through the sealed portion of thechannel system 178 of the cushion layer 162 162a. This assures that thegel pouches 184 remain fluid tight and substantially confine a fluidtherein without leaking due to the apertures 182.

FIG. 13 illustrates a perspective view of an assembly of anotherembodiment of a climate controlled seat assembly 150 150b. The climatecontrolled seat assembly 150 150b of FIG. 13 is substantially similar tothe climate controlled seat systems 150 150a of FIG. 7 and FIG. 10. Theclimate controlled seat assembly 150 150b of FIG. 13 includes a climatecontrolled system 152, a frame 154, a cushion 156 156b, comprising acushion intermediate layer 160 and 162 162b, and a cover 158. The frame154, the intermediate layer 160, the cover 158, and the climatecontrolled system 152 can be substantially similar to the climatecontrolled seat assembly embodiment of FIGS. 7 and 10. As describedbelow, the cushion layer 162 162b of FIG. 13 does present somedifferences from the cushion layer 162 162a shown in FIGS. 7-12.

With reference to FIGS. 14 and 15, the cushion layer 162 162b of theclimate controlled seat assembly 150 of FIG. 13 is preferably an aircomfort layer 162 162b. The air comfort layer 162 162b preferablyincludes a plurality of rectangular shaped air pockets 186 that extendupwards away from a base layer 190. The base layer 190 further comprisesapertures 188 which pass through the base layer and are in communicationwith the channel system 166 of the intermediate layer 160. The airpockets 186 are preferably configured on a grid layout with space inbetween adjacent air pockets 186. The apertures 188 preferably passthrough the base layer 190 in between the air pockets 186 so as to allowthe air pockets 186 to be substantially airtight. As similar to thecushion layer 162 162b of FIG. 11 and FIG. 12, the apertures 188 of thecushion layer 162 on FIG. 14 and FIG. 15 are arranged to closely followthe channel system 166 of the intermediate layer 160.

Although the embodiment of the climate controlled seat assembly 150 150bshown in FIGS. 14 and 15 shows an air comfort layer 162 162b withdiscrete rectangular shaped air pockets 186, other suitableconfigurations may be used. Such alternate configurations may utilizeair pockets 186 of varying size, shape, and orientation such as round oroctagonal cylinders in a circular, spiraling, or grid patterns. It isalso possible to form air pockets by fusing two layers similar to thefluid cushion layer 162 162b of FIGS. 10-12. Such a configuration myinclude a fused plurality of layers or a single formed pocket withpre-formed apertures as described above with reference to FIG. 10-12.Furthermore, in some embodiments, the air comfort layer 162 162b may beconfigured so that the air pressure inside the air pockets 186 isadjustable.

One advantage that may be realized by the embodiment of the climatecontrolled seat assembly 150 150b of FIG. 13-15 is that when the airflows from the intermediate layer 160 and through the base layer 190 ofthe cushion layer 162 162b the air may then be very evenly distributedusing the space between the adjacent pockets 186 as flow passages. Thiscould be particularly advantageous in instances where it may bedesirable to achieve an air distribution beyond the pattern of theapertures 188.

Although the embodiments of the climate controlled seat assembly 150150a, 150b shown in FIGS. 7 through 15 include a single climatecontrolled system 152, it may be appreciated by one skilled in the artthat multiple climate controlled systems 152 may be used. One suchembodiment is shown in FIGS. 16 and 17.

FIG. 16 is a top view of a frame 154 154c with two elongated holes 194passing through the frame 154. Two climate controlled systems 152 may bemounted in communication with the holes 194 passing through the frame154 of FIG. 16. This configuration allows for two sources of air toenter the climate controlled seat assembly 150 150c. One advantage ofsuch a configuration is that the air may have a shorter distance totravel to distribute air to the climate controlled seat assembly 150150c. This could be advantageous in that the air will have a shorterdistance to travel and thus a shorter time to alter the desiredtemperature (heating of cold air or cooling of hot air).

With reference to FIG. 17, correspondingly the intermediate layer 160160c may include a channel system 166 166c that includes two separatedistribution channels 172. The distribution channels 172 172c of theintermediate layer 160 160c of FIG. 17 are not connected by a centralportion. Each of the distribution channels shown in FIG. 17 areindependently fed air by a climate controlled system 152. In theembodiment shown in FIGS. 16 and 17, the climate controlled seatassembly 150 150c may include the layers 162 of FIG. 7, 10 or 13 as maybe appreciated by one skilled in the art.

Another feature of the frame 154 of FIG. 16 is that the holes 194 arelocated at distal ends of the distribution channels 172. This allows theair from the climate control systems 152 to enter at one end of thedistribution channels 172. In some other embodiments the holes 194 maybe located in a more central location of the frame 154 154c so as tofeed air to a central portion of the distribution channels 172 172c. Ithas also been contemplated that the location of the holes 194 may beused in combination with any of the aforementioned embodiments of theclimate controlled seat assembly 150 150c. One such example couldinclude a single hole 194 that is located at a distal end of adistribution channel 172 of FIG. 3 so as to feed air to the channelsystem 166 from a single distal end.

Although the embodiment of the climate control seat system has beendisclosed with reference to a seat back as illustrated in FIGS. 7-17, ithas also been contemplated that in some embodiments the system maycomprise other portions of seats such as side panels, arm rests or headrests. Such other embodiments could be easily achieved using the abovedisclosed technology.

Furthermore, it has been disclosed in the above described embodimentsthat the climate controlled system 152 of FIGS. 7-17 is attached to aframe 154. Other embodiments may include a remote climate control system152 that is in communication with the climate control seat assembly 150by means of passageways such as tubing or hoses. Such tubing or hosescan further be in communication with multiple portions of a seat such asarm rests or head rests by a branching system of passageways. Such aconfiguration could be achieved with a single or multiple climatecontrol systems 152.

Although the above described embodiments of the climate controlledsystems of FIGS. 1-17 have been described with reference to seats, ithas been contemplated that the technology may be also used with beds.One such embodiment may employ some of the features, aspects, oradvantages disclosed with reference to FIGS. 1-6. Such an embodiment mayemploy the apertures to be formed in a mattress or along sides of themattress, while the channels or recesses may be formed in support memberof the box spring or mattress foundation. Such an embodiment may beparticularly advantageous when using a viscoelastic mattress and mayalso be used with other mattresses such as those utilizing air or water.

Furthermore, another embodiment of a climate controlled systemcomprising a bed may utilize the technology described in FIGS. 7-17.Such an embodiment may comprise apertures to be formed in a mattresslayer and channels or recesses to be formed and a support member of abox support, which may comprise an intermediate layer. Additionally,such an embodiment of a climate controlled bed may comprise anadditional intermediate layer which may comprise a portion of a supportbox or a mattress. Such an embodiment comprising an additionalintermediate layer may include a mattress with an additional air cushionlayer wherein the additional air cushion layer may comprise aperturesfor the passage of air. Such an embodiment may be configured similarlyto the seat cushion 150 of FIG. 13 and may further comprise the aircushion layer to be adjustable.

To assist in the description of the disclosed embodiments, words such asupward, upper, downward, lower, vertical, horizontal, upstream, anddownstream have and used above to describe the accompanying figures. Itwill be appreciated, however, that the illustrated embodiments can belocated and oriented in a variety of desired positions.

Although this invention has been disclosed in the context of certainpreferred embodiments and examples, it will be understood by thoseskilled in the art that the present invention extends beyond thespecifically disclosed embodiments to other alternative embodimentsand/or uses of the invention and obvious modifications and equivalentsthereof. In addition, while a number of variations of the invention havebeen shown and described in detail, other modifications, which arewithin the scope of this invention, will be readily apparent to those ofskill in the art based upon this disclosure. It is also contemplatedthat various combinations or subcombinations of the specific featuresand aspects of the embodiments may be made and still fall within thescope of the invention. Accordingly, it should be understood thatvarious features and aspects of the disclosed embodiments can be combinewith or substituted for one another in order to form varying modes ofthe disclosed invention. Thus, it is intended that the scope of thepresent invention herein disclosed should not be limited by theparticular disclosed embodiments described above, but should bedetermined only by a fair reading of the claims that follow.

What is claimed is:
 1. A climate-controlled seating assembly,comprising: a cushion having an outer surface, said outer surfacecomprising a first side for receiving and supporting an occupant and asecond side, said second side facing in a generally opposite directionthan said first side; a plurality of fluid passages extending through aninterior of the cushion, from the first side to the second side of saidcushion, wherein said fluid passages are configured to facilitate atransfer of air from the second side to the first side of the cushion; asupport member positioned adjacent the second side of the cushion, saidsupport member comprising a front surface configured to contact at leasta portion of the second side of the cushion; wherein the support memberfurther comprises a rear surface, said rear surface being generallyopposite of the first surface; at least one fluid distribution systempositioned along the front surface of the support member, wherein saidat least one fluid distribution system comprises at least one recesswithin the front surface of the support member; wherein the at least onefluid distribution system does not extend to the rear surface of thesupport member; wherein the front surface of the support member directlycontacts the second side of the cushion member in areas adjacent the atleast one recess and along a majority of an interface between thesupport member and the cushion member; wherein the at least one recessof the at least one fluid distribution system forms at least one fluidchannel when the support member is secured to the cushion, said at leastone fluid channel being in fluid communication with at least one of thefluid passages of the cushion; and a fluid module in fluid communicationwith the at least one fluid channel; wherein, when in use, the fluidmodule is configured to deliver air into said at least one fluid channeland to at least some of the fluid passages, toward the first side of thecushion; and wherein, when in use, air directed into the at least onefluid channel is configured to be distributed at least partiallylaterally within said at least one fluid channel.
 2. The seatingassembly of claim 1 8, wherein the fluid module comprises a fluidtransfer device and at least one thermal conditioning device, said atleast one thermal conditioning device being configured to selectivelyheat or cool air.
 3. The seating assembly of claim 2, wherein the atleast one thermal conditioning device comprises at least one of athermoelectric device and a convective heater.
 4. The seating assemblyof claim 1 8, wherein the fluid module is positioned adjacent the rearsurface of the structural support member.
 5. The seating assembly ofclaim 1 8, wherein the fluid module is positioned at least partiallywithin the at least one fluid channel.
 6. The seating assembly of claim1 8, wherein the fluid module is positioned completely within the atleast one fluid channel.
 7. The seating assembly of claim 1, wherein thesupport member comprises a plastic material.
 8. The seating assembly ofclaim 1, A climate-controlled seating assembly, comprising: a cushionhaving an outer surface, said outer surface comprising a first side forreceiving and supporting an occupant and a second side, said second sidefacing in a generally opposite direction than said first side; aplurality of fluid passages extending through an interior of thecushion, from the first side to the second side of said cushion, whereinsaid fluid passages are configured to facilitate a transfer of air fromthe second side to the first side of the cushion; a structural supportmember positioned adjacent the second side of the cushion, saidstructural support member comprising a front surface facing the secondside of the cushion and configured to contact at least a portion of thesecond side of the cushion; wherein the structural support memberfurther comprises a rear surface, said rear surface being generallyopposite of the front surface; at least one fluid distribution systempositioned along the front surface of the structural support member,wherein said at least one fluid distribution system comprises at leastone recess within the front surface of structural support member;wherein the at least one fluid distribution system does not extend tothe rear surface of the structural support member; wherein the frontsurface of the structural support member directly contacts the secondside of the cushion member in areas of the second side adjacent the atleast one recess and along a majority of an interface between structuralsupport member and the cushion member; wherein the at least one recessof the at least one fluid distribution system forms at least one fluidchannel when the structural support member is secured to the cushion,said at least one fluid channel being in fluid communication with atleast one of the fluid passages of the cushion; a fluid module in fluidcommunication with the at least one fluid channel; wherein the at leastone fluid channel extends at least partially laterally along the secondside of the cushion; and wherein the structural support member comprisesa metallic material.
 9. The seating assembly of claim 1 8, wherein theseating assembly comprises a seat.
 10. The seating assembly of claim 18, wherein the seating assembly comprises a bed.
 11. The seatingassembly of claim 1, wherein the at least one fluid channel does notextend along an entire portion or substantially an entire portion of thesecond side of the cushion.
 12. The seating assembly of claim 1 8,wherein the at least one fluid channel comprises a U-shape, V-shape orsemi-circular shape.
 13. A climate-controlled seating assembly,comprising: a cushion having an outer surface, said outer surfacecomprising a first side for supporting an occupant and a second side,said second side facing in a generally opposite direction than saidfirst side; wherein at least a portion of the cushion is generally airpermeable so as to permit air to pass from the second side to the firstside of said cushion; a support member positioned adjacent the secondside of the cushion, said support member comprising a front surfaceconfigured to contact at least a portion of the second side of thecushion; wherein the support member further comprises a rear surface,said rear surface being generally opposite of the first surface; atleast one fluid distribution system formed along the front surface ofthe support member, wherein said at least one fluid distribution systemcomprises at least one recess within said front surface; wherein thesupport member comprises a first uniform thickness along the at leastone recess and a second uniform thickness along a remaining area of thesupport member, wherein the second uniform thickness is greater than thefirst uniform thickness; wherein the at least one recess of the at leastone fluid distribution system and the adjacent second side of thecushion together form at least one fluid channel when the support memberis secured to said cushion wherein, when in use, air from a fluid modulein fluid communication with the at least one fluid channel is configuredto be delivered into said at least one fluid channel and at leastpartially through an air permeable portion of the cushion, toward thefirst side of the cushion; and wherein, when in use, air directed intothe at least one fluid channel is configured to be distributed at leastpartially laterally within said at least one fluid channel.
 14. Theseating assembly of claim 13, wherein the seating assembly additionallycomprises the fluid module that is in fluid communication with the atleast one fluid channel.
 15. The seating assembly of claim 14 20,wherein the fluid module comprises a fluid transfer device and at leastone thermal conditioning device, said at least one thermal conditioningdevice being configured to selectively heat or cool air.
 16. The seatingassembly of claim 15, wherein the at least one thermal conditioningdevice comprises at least one of a thermoelectric device and aconvective heater.
 17. The seating assembly of claim 14 20, wherein thefluid module is positioned adjacent the rear surface of the structuralsupport member.
 18. The seating assembly of claim 14 20, wherein thefluid module is positioned at least partially within the at least onefluid channel.
 19. The seating assembly of claim 13, wherein the supportmember comprises a plastic material.
 20. The seating assembly of claim13, A climate-controlled seating assembly, comprising: a cushion havingan outer surface, said outer surface comprising a first side forsupporting an occupant and a second side, said second side facing in agenerally opposite direction than said first side; wherein at least aportion of the cushion is generally air permeable so as to permit air topass from the second side to the first side of said cushion; astructural support member positioned adjacent the second side of thecushion, said structural support member comprising a front surfacefacing the second side of the cushion and configured to contact at leasta portion of the second side of the cushion; wherein the structuralsupport member further comprises a rear surface, said rear surface beinggenerally opposite of the front surface; at least one fluid distributionsystem formed along the front surface of the structural support member,wherein said at least one fluid distribution system comprises at leastone recess within said front surface; wherein the structural supportmember comprises a first uniform thickness along the at least one recessand a second uniform thickness along a remaining area of the structuralsupport member, wherein the second uniform thickness is greater than thefirst uniform thickness; wherein the at least one recess of the at leastone fluid distribution system and the adjacent second side of thecushion together form at least one fluid channel when the structuralsupport member is secured to said cushion, the fluid channel being incommunication with the portion of the cushion that is generally airpermeable; a fluid module in fluid communication with the at least onefluid; wherein the at least one fluid channel extends at least partiallylaterally along the second side of the cushion; and wherein thestructural support member comprises a metallic material.
 21. The seatingassembly of claim 13 20, wherein the seating assembly comprises a seat.22. The seating assembly of claim 13 20, wherein the seating assemblycomprises a bed.
 23. The seating assembly of claim 13, wherein the atleast one fluid channel does not extend along an entire portion orsubstantially an entire portion of the second side of the cushion. 24.The seating assembly of claim 13 20, wherein the at least one fluidchannel comprises a U-shape, V-shape or semi-circular shape.
 25. Theseating assembly of claim 13 20, wherein the portion of the cushion thatis generally air permeable comprises an air permeable material so thatair can be selectively transferred through a portion of the cushion,from the second side to the first side of the cushion.
 26. The seatingassembly of claim 13, wherein the cushion comprises a plurality of fluidpassages that extend from the second side to the first side of thecushion.